Movable Battery Module Electrical Connection with Prestressing
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Solution Overview
Problem
High voltage batteries in motor vehicles face the challenge of preventing electrical connections between battery modules and other conductive components during accidents, which can lead to short circuits and electrical hazards.
Innovation Solution
Incorporating a prestressing element within the battery module housing that moves electrical connection elements between a connection and protective position, allowing for a destruction-free disconnection of battery modules during collisions, thereby preventing electrical contact with other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical connection elements are arranged outside the module housing for easy connection, then ease of operation is improved, but safety is worsened due to risk of electrical contact with conductive components during accidents
Solution Approach 1:
The electrical connection element is designed to be movable between a connection position (outside the housing) and a protective position (inside the housing). A prestressing element continuously exerts force to move the connection element into the protective position, ensuring that during normal operation the element is accessible for connection, but during accidents it automatically retracts inside the housing to prevent electrical contact with conductive components.
2Strength
If battery modules are rigidly connected for structural stability, then strength is improved, but ability to disconnect during accidents is worsened
Solution Approach 1:
The connecting unit incorporates a movable electrical connection element that can transition between connected and disconnected states. The prestressing element ensures that upon relative movement of modules during an accident, the connection element automatically disconnects and retreats into the housing, providing both structural stability during normal operation and automatic disconnection capability during accidents.
Solution Approach 2:
The prestressing element continuously applies force in advance to keep the electrical connection element in the protective position inside the housing. This preliminary action ensures that if relative movement occurs during an accident, the connection element is already predisposed to disconnect and retreat, preventing electrical contact before it can occur.
3Productivity
If electrical connection elements are kept outside the housing for rapid connection, then productivity is improved, but safety is worsened due to exposure to mechanical loads during accidents
Solution Approach 1:
The electrical connection element is designed with mobility between outside (connection) and inside (protective) positions. During normal operation, it remains outside for rapid connection, improving productivity. During accidents, the prestressing element automatically moves it inside the housing, protecting it from mechanical loads and preventing harmful electrical contact.
Solution Approach 2:
The prestressing element continuously exerts force to maintain the electrical connection element in the protective position inside the housing as a preliminary safety measure. This ensures that if mechanical loads occur during accidents, the connection element is already protected inside the housing, preventing exposure to harmful factors before they can cause damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures reliable and rapid disconnection of battery modules in collision scenarios, preventing high voltage short circuits and ensuring safety by maintaining electrical isolation.
Implementation Method 1
a prestressing element (9) which is arranged within the module housing (4) and is connected to the connection element (5, 6), wherein the connection element (5, 6), which is connected to the prestressing element (9), is arranged on the battery module (2, 3) such that it is movable between a connection position and a protective position
Data Source
AI summary
A high voltage battery has at least two battery modules that each have a module housing and an electrical connection element to electrically connect the battery modules. A battery module has a prestressing element which is arranged within the respective module housing and is connected to the respective electrical connection element. The electrical connection element connected to the prestressing element is arranged on the battery module such that it is movable between a connection position, in which the electrical connection element is guided through a through-hole in the module housing, and a protective position, in which the electrical connection element is arranged completely within the module housing. The prestressing element prestresses the electrical connection element in a direction of the protective position. The connection element in the connection position is connected to another battery module via at least one connecting unit. The connecting unit is configured such that the connection produced by the connecting unit can be released in a destruction-free manner or with destruction of the connecting unit by a movement of the mutually electrically connected battery modules relative to one another in a movement direction which extends transversely to a prestressing direction in which the connection element is prestressed by the prestressing element.